Ceramic particulate trap and method of making the same

Abstract

A ceramic particulate trap is disclosed and manufactured from a plurality of ceramic support plates each having a plurality of grooves in an upper surface and a lower surface thereof extending in a direction of fluid flow. Each groove in the upper surface of the ceramic support plate having an open upstream end and a closed downstream end while each groove in the lower surface of the ceramic support plate includes a closed upstream end and an open downstream end. A ceramic foam layer is then placed on and supported by the ceramic support plates and spans the open surface of the plurality of grooves formed in the upper surface of the support plate. The support plate being manufactured by conventional relatively inexpensive extrusion processes provides structural support for the ceramic foam layer. As the fluid containing the entrained particulate matter passes through the open ends of the grooves in the top surface of the ceramic plate, this fluid is restricted to pass through the ceramic foam layer and into the corresponding grooves in the lower surface of the support plate positioned adjacent the first support plate. By doing so, the particulate matter entrained within the fluid will be trapped in the ceramic foam layer supported by the ceramic support plate.

I claim: 
     
       1. A particulate trap for filtering particulate matter entrained in a fluid passing therethrough comprising: at least one substantially non porous support plate having a plurality of grooves formed in an upper surface thereof extending in a direction of fluid flow and ribs formed between each of said grooves, with each of said grooves having an open upstream end, a closed downstream end and an open surface extending in said direction of fluid flow; and   a ceramic foam layer for filtering said particulate matter positioned on and supported by said ribs so as to overly said open surface;   wherein said fluid is restricted to flow through said grooves and through said ceramic foam layer such that said entrained particulate matter is removed from said fluid during the flow of said fluid through said particulate trap.   
     
     
       2. The particulate trap as defined in claim 1, wherein said support plate further includes at least one groove formed in a lower surface thereof extending in said direction of fluid flow having an open downstream end and a closed upstream end. 
     
     
       3. The particulate trap as defined in claim 2, wherein a plurality of said support plates are stacked one upon the other such that each respective ceramic foam layer is disposed between said grooves formed in said upper surface of a first plate and said grooves formed in said lower surface of an adjacent support plate positioned atop said first support plate, such that said fluid is further restricted to flow through said grooves in said lower surface of said adjacent support plate after passing through the respective ceramic foam layer. 
     
     
       4. The particulate trap as defined in claim 3, further comprising a top support plate and a bottom support plate, wherein said top support plate includes grooves only in a lower surface thereof, and said bottom plate includes grooves only in an upper surface thereof. 
     
     
       5. The particulate trap as defined in claim 1, wherein said support plate is formed by extrusion. 
     
     
       6. A particulate trap for filtering particulate matter entrained in a fluid passing therethrough comprising: a plurality of substantially non porous support plates stacked one upon the other each having a plurality of grooves formed in an upper surface and a lower surface thereof, each of said grooves extending in a direction of fluid flow and having an upstream end, a downstream end and an open surface extending from said upstream end to said downstream end with each of said grooves of said upper surface having a closed downstream end and each of said grooves of said lower surface having a closed upstream end; and   a plurality of filtering means for filtering said particulate matter, a respective one of said filtering means being supported by a respective one of said support plates so as to overly said open surface of said upper grooves and to underlie said open surface of said lower grooves;   wherein said grooves formed in said upper surface of a first support plate communicate with said grooves formed in said lower surface of an adjacent support plate with said fluid being restricted to flow into said grooves in said upper surfaces of said support plates, through said respective filtering means supported thereon and out said grooves formed in said lower surfaces of said support plates.   
     
     
       7. The particulate trap as defined in claim 6, wherein said plurality of filtering means are ceramic foam layers. 
     
     
       8. The particulate trap as defined in claim 6, further comprising a top support plate and a bottom support plate, wherein said top support plate includes grooves only in a lower surface thereof, and said bottom support plate includes grooves only in an upper surface thereof. 
     
     
       9. The ceramic particulate trap as defined in claim 6, wherein said support plate is formed by extrusion. 
     
     
       10. The particulate trap as defined in claim 9, wherein said extruded support plate is formed of a nonporous ceramic material. 
     
     
       11. A filter element for filtering particulate matter entrained in a fluid passing therethrough comprising: a substantially non porous support plate having a plurality of upper grooves formed in an upper surface thereof extending in a direction of fluid flow and ribs formed between each of said grooves with each of said upper grooves having an open upstream end, a closed downstream end and an open surface extending in said direction of fluid flow, and a plurality of lower grooves formed in a lower surface thereof extending in said direction of fluid flow with each of said lower grooves having a closed upstream end, an open downstream end and an open surface extending in said direction of fluid flow; and   a ceramic foam layer for filtering said particulate matter positioned on and supported by said ribs so as to overly said open surface of said upper grooves;   wherein said fluid is restricted to flow through said upper grooves and through said ceramic foam layer such that said entrained particulate matter is removed from said fluid during the flow of said fluid through a particulate trap formed of a plurality of said filter elements.